Jackshaft Removal; Jackshaft Installation; Adjustments; Chaincase Drive Tension - Polaris 2007 Two Stroke Service Manual

Jackshaft Removal

1. Remove the drive belt (J).
2. Remove the driven clutch (N) and make note of the
placement of the washers (O).
3. Drain the chaincase fluid.
4. Remove the chaincase cover.
5. Remove the cotter pin on the upper sprocket.
6. Apply parking brake.
7. Remove the upper sprocket nut.
8. Remove the lower sprocket retaining bolt.
9. Loosen the chain tensioner.
10. Remove the upper and lower sprockets and chain from
chaincase.
11. Release the parking brake.
12. Remove the bearing flange on the driven clutch side (I).
13. Remove the jackshaft assembly (E,F,H) from the brake disc
(D) and chassis by tapping on the end of the jackshaft (F)
with a soft face hammer.
14. This will also remove the o-ring (B) and seal (C).
15. Inspect jackshaft in bearing contact area. If diameter is
0.001" (.025 mm) less than non-contact area, replace the
jackshaft.

Jackshaft Installation

1. Install jackshaft installation tool PN 2871296 onto the
threads of the jackshaft.
2. Insert the new jackshaft assembly through the brake disk
and install a new seal (C) and o-ring (B).
3. Remove the jackshaft installation tool.
4. With the jackshaft through the chaincase, install the
jackshaft alignment tool PN 2871535 and secure with the
flat washer and castle nut.
5. Tighten the castle nut securely to ensure positive bearing
and jackshaft seating to chaincase.
6. If shaft is not centered, tap shaft with a soft faced hammer
until centered. This will align the upper chaincase bearing
in the chaincase bore.
7. Once the correct jackshaft alignment has been achieved,
install lock nuts on the chaincase mounting bolts and torque
them to 20 ft-lb (27 N-m).
8. Remove the jackshaft alignment tool from chaincase.
9. Install jackshaft flangette (I) and bolts (AA). Align grease
hole in bearing with hole or fitting in flangette. Torque nuts
to 11 ft-lb (15 N-m).
10. Place the same amount of washers (O) on the drive clutch
end of the jackshaft.
11. Install the driven clutch, spacer (K), and washers (L) and
torque the retaining bolt (M) to 17 ft-lb (23 N-m).
12. Install the belt.
FINAL DRIVE/BRAKES
13. Check clutch alignment. See "Clutch Alignment / Offset"
on page 6.14.

ADJUSTMENTS

Chaincase Drive Tension

NOTE: It may be necessary to remove the exhaust
pipe and resonator to access this area.
1. Elevate the rear of the machine so that the track is off the
floor.
2. Rotate the driven clutch counterclockwise to move all the
chain slack to the tensioner side.
3. Lock the parking brake.
4. Loosen the adjuster bolt jam nut (A).
5. Finger tighten the adjuster bolt (B).
6. Back off the adjuster bolt 1/4 turn out (counterclockwise)
7. Tighten the jam nut while holding the adjuster bolt.
8. Release the parking brake.
A
B
7
7.11